JPS62253439A - Manufacture of decorative sheet - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION Object of the Invention (Industrial Application Field) The present invention relates to a method for producing a decorative sheet having a decorative layer formed by raising on its surface.

(Prior technology) In various synthetic resin molded products such as automobile interior parts and indoor equipment products, it is necessary to give an excellent appearance, hide defects such as scratches and uneven color on the resin surface, and give a sense of luxury. Therefore, it is useful to decorate the surface.

Furthermore, it is desirable to form a flocked layer on the surface of the resin molded product, not only to solve the problem of appearance but also to improve the feel to the touch.

As a method for forming this flocked layer, an electrostatic flocking method has been generally used.

In recent years, there has been a trend toward favoring buckskin-like flocked hair, which looks luxurious and has an excellent feel to the touch.

(Problems to be Solved by the Invention) However, in the electrostatic flocking method described above, in order to bond the piles to the surface of the molded product, expensive piles and adhesives are required separately, and furthermore, at least the bonding process and the electrostatic Two processes are required: the hair transplantation process. Therefore, there are problems in that the material cost increases, as well as the manufacturing time and manufacturing cost.

In addition, in order to form a product using the electrostatic flocking method, flocking work must be performed on each completed product.
In order to process a plurality of products at once, a large-scale device is required, and when this large-scale device is employed, there is a problem in that the manufacturing cost increases.

Furthermore, this electrostatic flocking method has the problem that it is very difficult to produce fabrics that have the buckskin-like feel to the touch and look luxurious.

Therefore, the object of the present invention is to provide a decoration that does not require the expensive piles and adhesives used in the above-mentioned flocking method, and that can be simply pasted onto a molded product, giving it a high-class appearance and an excellent feel. It is an object of the present invention to provide a method for producing a decorative sheet provided with layers.

Structure of the Invention (Means for Solving the Problems) In order to solve the above-mentioned problems, the present invention applies a liquid resin containing a foaming agent to the surface of a cloth, and blows gas from the back side of the cloth to form the liquid resin. The method is to foam and harden the resin while raising it.

(Function) When gas is blown from the back side of a cloth whose surface is coated with liquid resin, the gas passes through the gaps of the cloth and penetrates to the front side. This gas passes through the holes in the cloth, narrows it down, increases its pressure, and penetrates through the liquid resin on the surface of the cloth.

At this time, since bubbles are formed in the resin due to the foaming agent, the air often penetrates through the bubbles. As a result of this gas penetration, the resin in the vicinity stands up in a tufted manner, forming a long and narrow pile-like raised portion, and the other portions are roughened in an uneven manner by the air bubbles. In parallel with this gas penetration, the liquid resin begins to harden after being applied, so the raised portion is cured in an erect state, giving it a high-class look as a whole and an excellent feel to the touch. A decorative sheet is formed.

(Example) Hereinafter, an example in which the present invention is applied to a skin attached to the surface of a center pillar interior material of an automobile will be described with reference to FIGS. 1 to 3.

First, to explain the center pillar interior material formed by this method, as shown in FIG. 2, an adhesive is applied to the surface of a base material 1 made of ABS resin to form an adhesive layer 2. ing.

A skin 10 of this embodiment is adhered to the surface of the adhesive layer 2, and this skin 10 will be described below.

This skin 10 is composed of a nonwoven fabric 3 as a breathable fabric bonded to an adhesive layer 2, and a decorative portion 4 integrally formed on the surface thereof.

The decorative portion 4 is composed of an uneven base portion 5 (shown only in FIG. 3) that is integrally joined to the nonwoven fabric 3, and a raised portion 6 that stands up three-dimensionally from the base portion 5. . Each of the raised portions 6 is formed to protrude in a pile shape, and has a moist feel and flexibility, and together with the uneven shape of the base portion 5, the overall appearance is similar to that of buckskin. It is designed to have a tactile feel.

The decorative portion 4 is made of a material obtained by adding 1 to 10 parts by weight of an ADCA (azodicarbonamide) blowing agent or DPT (dinitropentamethylenetetramine) to 10 parts by weight of liquid PVC (polyvinyl chloride) resin. It is made of a material in which a urea-based auxiliary agent is added to the
5 parts of blowing agent and auxiliary agent per 100 parts by weight of PVC resin
It is formed by adding parts by weight.

The center pillar interior material constructed as described above has approximately the same appearance and feel as the conventional center pillar interior material to which natural buckskin is pasted, due to the raised portion 6 of the skin 10 pasted on the surface. This gives it an overall sense of luxury.

Next, a method for manufacturing the center biller interior material constructed as described above will be explained with reference to FIG. 1.3.

First, among the devices used in this method, the device for forming the skin 1O will be explained. In front of the delivery shaft 11 (showing the right side in Fig. 1), which is equipped with a delivery mechanism for delivering the O-ru-shaped nonwoven fabric 3. A nozzle 12 of a coating mechanism for coating the nonwoven fabric 3 with a liquid resin containing a foaming agent is provided. A plurality of infrared lamps 13 are provided in front of the nozzle 12 to spray a certain amount of the liquid resin solvent. In front of the infrared lamp 13, there is provided an air outlet 14 of an air blowing mechanism that blows hot air H from below the nonwoven fabric 3 to form a raised portion 6 on the surface. Accelerates resin curing.

Next, a method for forming the center pillar interior material of this example using this apparatus will be explained.

First, the nonwoven fabric 3 wound into a roll is placed on the delivery shaft 11.
The tip of the delivery shaft 11 is guided to the nozzle 12 by rotation of the delivery shaft 11.

When the nonwoven fabric 3 is placed in the nozzle 12 by this operation, liquid PVC resin containing a foaming agent is poured from the nozzle 12 to form a resin layer 15.

Thereafter, the solvent in the liquid resin layer 15 is blown away to some extent by the infrared lamp 13, and hot air H heated and pressurized (in this example, at 180 degrees ) is sprayed from the air outlet 14.

Then, the hot air H passes through the fine mesh of the nonwoven fabric 3 and is blown onto the resin layer 15.
With this pressure, the portion of the resin layer 15 that is hit by the air is raised. However, since a plurality of bubbles 8 are formed in the resin layer 15 during foaming, the hot air H tends to advance to the bubble portion of the cavity. Further, the hot air H passes through the fine meshes of the nonwoven fabric 3, so that the blowing pressure is further increased. Therefore, the hot air H passes through the 8 portions of the air bubbles in the resin layer 15.
As shown in FIG. An elongated pile-like raised portion 6 is formed. Therefore, the resin layer 15 is raised by the hot air H.
It is formed in two layers: and a base portion 5 whose surface is roughened into an uneven shape that does not stand up. Note that the curing of the liquid resin is accelerated by spraying the hot air H.

Since each pile of the raised portion 6 has a moist feel and flexibility, the decorative portion 4 as a whole has a buckskin-like appearance and feel.

Finally, the skin 10 thus formed is trimmed to be larger than the base material 1, and is adhered to the ABS resin base material 1 formed by injection molding and coated with adhesive on the surface. When the outer periphery is wrapped around the back surface of the base material 1, it is possible to form the center pillar interior material whose entire surface is formed in a buckskin style.

As described above, according to the present embodiment, the surface decoration portion 4 can create a buckskin-like appearance and feel, so that the entire center pillar interior material can have a luxurious feel. Further, since the base portion 5 is roughened with a foaming agent, the entire surface of the decorative portion 4 can have an appearance closer to that of natural buckskin.

Furthermore, according to the above method, decoration can be applied without using the electrostatic flocking method that requires expensive piles and adhesives, and it is possible to create a buckskin-like appearance that is very difficult to achieve with the electrostatic flocking method. You can easily create a tactile feel. Further, this buckskin-like decorative portion 4 can be manufactured at a much lower cost than when actual buckskin is used.

Furthermore, since the process of forming the skin 10 is performed in a series of continuous steps, it can be manufactured in a very short manufacturing time.

Furthermore, since this skin 10 is formed in a sheet state,
Components other than the center pillar interior material of this embodiment can be easily modified and implemented.

In addition, since the liquid resin has entered between the meshes of the nonwoven fabric 3, a mechanical anchor effect occurs, and the nonwoven fabric 3 and the base 5
It is strongly bonded to.

It should be noted that the present invention is not limited to the above-mentioned embodiments, and can be modified and embodied as shown below, for example.

(1) In addition to the nonwoven fabric of the above embodiment, the cloth 3 may be a plain woven fabric, a twill woven fabric, a satin woven fabric, or even a knitted fabric. In this way, the raised portion 6 becomes three-dimensional due to the three-dimensional configuration of the stitches, making the appearance more interesting.

(2) The liquid resin may be a liquid resin such as polyester or polyurethane in addition to the PVC resin of the above embodiment, and furthermore, the following resins may be used. however,
In this case, it is necessary to add the solvent shown in parentheses. In this way, the hardness, thickness, and length of the raised portion 6 can be changed arbitrarily.

■Polyamide resin (alcohol) ■Polyvinyl chloride (tetrahydrofuran) (3) The pressure and temperature of the hot air H can also be arbitrarily changed depending on the length and diameter of the raised portion 6 to be formed, and the The clay used as the binder resin can also be arbitrarily changed depending on the length and diameter of the raised portion 6.

(4) In addition to the center pillar interior material of the above-described embodiment, the present invention is applicable to various resins for automobile interior parts such as automobile door linings, ceiling materials, instrument panels, and steering wheel covers, as well as furniture, fittings, wall materials, etc. It is also possible to embody it as a decorative sheet attached to a molded product.

Effects of the Invention As detailed above, the method of the present invention has the excellent effect of easily and inexpensively producing a decorative sheet that looks luxurious and has an excellent feel to the touch. play.

[Brief explanation of drawings]

FIG. 1 is a schematic diagram showing the manufacturing process of the present invention, FIG. 2 is a partial sectional view showing a center pillar interior material for an automobile molded by the manufacturing method of the present invention, and FIG. 3 is a schematic diagram showing the manufacturing process of the present invention. , is a partially enlarged cross-sectional view showing a state in which raised portions are formed on the surface of the resin layer. Cloth...3 Raised part...6

Claims (1)

[Claims] 1. Applying a liquid resin containing a foaming agent to the surface of the cloth (3) and raising the liquid resin (6) by blowing gas (H) from the back side of the cloth (3). A method for producing a decorative sheet, which is characterized by foaming and curing the sheet. 2. The method for manufacturing a decorative sheet according to claim 1, wherein the cloth (3) is a nonwoven fabric. 3. Claim 1, wherein the blowing agent is an ADCA (azodicarbonamide) blowing agent or DPT (dinitropentamethylenetetraamine), and the liquid resin is a PVC (polyvinyl chloride) resin. A method for producing a decorative sheet as described in section.